VOLTECH ENGINEERS PRIVATE LIMITED.

OPERATIONAL CONTROL PROCEDURE

OCP NO: 08

PRE COMMISSIONING TEST PROCEDURE FOR BUS BAR

1.0 Purpose
This procedure is prepared to carry out various pre- commissioning tests to be conducted in systematic
manner for Panel Bus bar to ensure the healthiness and performance of the Bus Bar
2.0 Scope
This procedure covers the Pre commissioning test for Bus Bar as for the following
1. CRM Test
2. Insulation Resistance Test
3. High Voltage (Hi-Pot)AC Test

3.0 Responsibility
Unit Head / Regional managers:
Unit heads / Regional managers have overall responsibility for health and safety management and role
includes:
 Planning and scheduling of activities with a view to execute the project
 Identify significant health and safety and eliminate or minimize them
 Maintaining all legal and statutory requirement
 Assist the safety team to conduct the safety training and audit at sites
 Ensure all safety rules and regulations are followed at work sites

Site Engineers:
Site engineers are responsible for all aspects of health and safety on site and are accountable to the Unit
head / Regional manager. Their roles include:
 Report any issue affecting health and safety issues at the work sites to the regional manager / unit
head / safety team
 Coordinate with end customer / client for the taking work permit and returning work permit
 Communicating the work content / hazard involved to working group through the medium of
Toolbox meeting before commencement of work every day
 Initiating proactive measures to minimize / eliminate accidents
 Reporting in detail in the event of incident
 Ensure effective use of appropriate PPE
 Ensure the quality of job at all times without any compromise on safety
 “Stop Work” in the event of any serious safety violation

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OPERATIONAL CONTROL PROCEDURE
OCP NO: 08

Safety Manger / Regional Safety Engineers:

Safety manger / Regional safety engineers are responsible for providing health and safety advice and
guidance to their Unit head/ Regional manager, site engineers and their roles include:
 Ensuring implementation of all instruction and procedures based on the occupational health and
safety
 Communicating all safety rules, regulations and practices to all site engineers / regional manager/
unit head
 Follow up for the closure of audit non conformances and help regional mangers / unit head to take
corrective action and preventive action
 Report and investigate all the incidents / Near misses to the top management
 Create awareness amongst site engineers / regional managers and also organize the regular training
program.
 Ensure that Tool box talk meetings are in being conducted daily at site and the workers are aware of
all the hazards at the work site
 Ensure adequate PPE’s and safety equipment as are required are available at sites and are being
used at site appropriately
 Reporting of any issues affecting the health and safety at the work site to the unit head / Regional
managers
 Ensure basic first aid facilities are available at sites
 Ensure that no unsafe act is performed at any site
 Ensuring that any unsafe condition observed at site is eradicated at the earliest
 Issuing of safety challans in the event of any safety violations.

4.0 Working Activity and descriptions

4.1 Pre-Testing Checks
 Check out the working condition of ELCB(30 mA)
 Check the insulation of power cable for equipment
 Ensure proper earthing and rubber mats available at the work location.
 Calibrated Testing equipment should be used and calibration reports available with engineers for
the same
 Check out the insulates hand tools available with the technician
 Ensure the Healthiness of the test leads (Check for any insulation Damages)
 Ensure appropriate PPE’s available at sites

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OPERATIONAL CONTROL PROCEDURE
OCP NO: 08

4.2 Resources – Tools and Equipment Required

For CRM Test:

a. CRM kit
b. Connecting cables
c. Insulated Hand tools

For Insulation Resistance measurement Test (IR Test):

a. Test Leads
b. 500 V, 5000 V Insulation Tester
c. Insulated Hand Tools
For High voltage Test (Hi-pot test):
a. High Voltage Test Kit
b. Test Leads
c. 500 V, 5000 V Insulation Tester
d. Clamp meter
e. Insulated Hand Tools
4.3 Operational Sequence of work(Test Procedure)

Contact Resistance Measurement (CRM) Test – Bus Bar

 Take the work permit from the client

 Ensure zero energy in the Bus Bar
 Disconnect Bus bar from the transformer
 Connect the earth from CRM kit to earth plate or earth pit
 Connect the CRM kit voltage leads to across the(R-Phase) Bus Bar joint
 Connect the CRM kit current leads to across the(R-Phase) Bus Bar Joint, at the same time
Voltage leads should be connected inside the current leads
 Ensure that all the connections are connected properly
 Connect the CRM kit in A.C supply extension board with ELCB rated with 30 mA
 Apply the rated current to the Bus bar
 Note down the resistance value from the CRM kit
 Repeat the above procedures for remaining (YØ & BØ)Phases for CRM Test
 Switch off the supply to the CRM Kit and disconnect the connections

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OPERATIONAL CONTROL PROCEDURE
OCP NO: 08

BUS BAR CRM TEST

IR TEST BETWEEN PHASE TO EARTH(BUS BAR):

 Check the Bus Bar tightness and panel earthing

 Connect the Megger Positive lead with RØ Bus Bar
 Then connect the Megger Negative lead with earth
 Select the required voltage range in megger
 Switch “ON” the megger and press the test button take down the reading
 Switch “OFF” the Megger
 Discharge the potential from the bus bar with respect to earth
 Repeat the above steps for the other Bus bar phases (YØ & BØ)

Y
MEGGER

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OPERATIONAL CONTROL PROCEDURE
OCP NO: 08
IR TEST BETWEEN PHASE TO PHASE (BUS BAR):

 Connect the Megger across the RØ-YØ Bus Bar

 Select the required voltage range in megger
 Switch “ON” the megger and press the test button take down the reading
 Switch “OFF” the Megger
 Discharge the potential from the Bus bar with respect to earth
 Repeat the above steps for the other Bus bar phases (YØ-BØ) &( BØ-RØ)

MEGGER Y

High Voltage(Hi-Pot ) AC Test – 11kv Bus Bar:

 Take the work permit from the client

 Check the bus bar terminal should be no voltage and earthing
 Ensure the during the High voltage test all other equipment’s related to the Bus bar installation
such as switches, instrument transformers, Cable etc., must be earthed and clearance should
be maintained from the other equipment and frame work to prevent flashover.
 Connect the controller kit and Transformer
 Connect the Hi-Pot kit with ELCB 30mA
 Connect the test (Transformer kit)HV lead to the RØ Bus bar conductor

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OPERATIONAL CONTROL PROCEDURE
OCP NO: 08
 Looped (Shorted) the other conductors (BØ & YØ) and connect it to the earth
 Switch “ON” the test kit and apply voltage to the Bus bar and after taking the reading
 Switch “OFF” the test kit
 Use discharge rod to discharge the potential from the Bus bar
 Repeat the above steps for measuring the other phases (YØ & BØ)

HI – POT Y
TRANSFORMER
OUTPUT

HI-POT CONTROLLER KIT HI- POT TRANSFORMER

HI POT TEST FOR BUS BAR

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OPERATIONAL CONTROL PROCEDURE
OCP NO: 08

4.4 Control Measures

 OCP for IR and Hi-Pot test for Bus bar is available with testing engineers
 Ensure PTW system in place for the particular Panel
 Ensure all supply to the equipment is dead
 Unauthorized persons should not be allowed to enter Testing area
 Barricade the testing area with warning tape
 Proper supervision, conduct job specific toolbox meeting and barricading the entire area
 Calibrated equipment shall be used
 Insulated hand tools shall be used
 Avoid joints for power cable and supply has to be taken via ELCB
 Avoid Lone working
 Use arc flash suits and shied for Hi-Pot test
 Use appropriate insulated hand gloves

5.0 Final Checks & Restoration of work area after completion of work:

 Disconnect the temporary supply and remove the barricading tapes

 Ensure no loose materials / tools are kept in and around the area
 Leave the place by keeping it tidy and clean

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OPERATIONAL CONTROL PROCEDURE
OCP NO: 08

6.0 Personal Protective Equipment (PPE):

Personal
Protective
Equipment

YES / NO Yes Yes Yes Yes

Personal
Protective
Equipment

YES / NO Yes Yes Yes Yes

7.0 Communication and signing off register:

Communicate to all employees in Tool box talk and ensure it is signed by all personnel

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